US10143266B2 - Article of footwear with a lattice sole structure - Google Patents

Abstract

An article of footwear includes an upper and a sole structure. The sole structure can be manufactured using a customized cushioning sole system. A user's foot morphology and/or preferences may be used to design the sole structure. The sole structure can also include a lattice structure made by a three-dimensional printer. The sole structure includes compartments to receive air bladder components.

Description

BACKGROUND

The present embodiments relate generally to articles of footwear, and in particular to articles with cushioning provisions and methods of making such articles.

Articles of footwear generally include two primary elements: an upper and a sole structure. The upper is often formed from a plurality of material elements (e.g., textiles, polymer sheet layers, foam layers, leather, synthetic leather) that are stitched or adhesively bonded together to form a void on the interior of the footwear for comfortably and securely receiving a foot. More particularly, the upper forms a structure that extends over instep and toe areas of the foot, along medial and lateral sides of the foot, and around a heel area of the foot. The upper may also incorporate a lacing system to adjust fit of the footwear, as well as permitting entry and removal of the foot from the void within the upper. In addition, the upper may include a tongue that extends under the lacing system to enhance adjustability and comfort of the footwear, and the upper may incorporate a heel counter.

The sole structure is secured to a lower portion of the upper so as to be positioned between the foot and the ground. In athletic footwear, for example, the sole structure includes a midsole and an outsole. The midsole may be formed from a polymer foam material that attenuates ground reaction forces (i.e., provides cushioning) during walking, running, and other ambulatory activities. The midsole may also include fluid-filled chambers, plates, moderators, or other elements that further attenuate forces, enhance stability, or influence the motions of the foot, for example. The outsole forms a ground-contacting element of the footwear and is usually fashioned from a durable and wear-resistant rubber material that includes texturing to impart traction. The sole structure may also include a sockliner positioned within the upper and proximal a lower surface of the foot to enhance footwear comfort.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.

FIG. 1 illustrates an embodiment of the use of a device for obtaining three dimensional foot data;

FIG. 2 schematically illustrates an embodiment of a computer screen image of digitized three-dimensional foot data;

FIG. 3 schematically illustrates an embodiment of a computer screen image of a template for a sole structure;

FIG. 4 schematically illustrates an embodiment of a computer screen image of a digitized model of a customized sole structure;

FIG. 5 illustrates an embodiment of a three-dimensional printer and a method of printing a sole structure;

FIG. 6 is an isometric side view of an embodiment of a sole structure;

FIG. 7 is an isometric side view of an embodiment of a sole structure;

FIG. 8 is an isometric side view of an embodiment of a sole structure;

FIG. 9 is an isometric side view of an embodiment of a sole structure;

FIG. 10 is an isometric side view of an embodiment of a sole structure and components;

FIG. 11 is an isometric side view of an embodiment of a sole structure with components;

FIG. 12 is a cut-away view of the sole structure shown inFIG. 11;

FIG. 13 is an isometric bottom view of an embodiment of a sole structure and components;

FIG. 14 is an isometric side view of an embodiment of a sole structure and components;

FIG. 15 is an isometric side view of an embodiment of a sole structure with components; and

FIG. 16 is a cut-away view of an embodiment of an article of footwear including a sole structure.

DETAILED DESCRIPTION

In one aspect, the present disclosure is directed to a customized cushioning sole system for an article of footwear. The system includes a sole structure with a lattice structure, where the lattice structure has an upper side. The upper side is has a geometry corresponding to the contours of a foot. The lattice structure has a plurality of interstices, where the plurality of interstices includes a first interstice. The upper side further includes a first aperture that is proximate to the first interstice. The first aperture is also in fluid communication with the first interstice. The first interstice contains a first air bladder component.

In another aspect, the present disclosure is directed to an article of footwear including a customized sole structure. The customized sole structure includes an upper side, a bottom side, a peripheral side, and a plurality of interstices. The upper side further includes a plurality of apertures. The upper side includes contours that correspond to the contours of a sole of a wearer's foot. The custom lattice structure also includes a plurality of air bladder components, including a first air bladder component, an interior area bounded by the upper side, the bottom side, and the peripheral side, where the interior area contains the plurality of interstices. The plurality of interstices includes a first interstice, wherein the first interstice includes the first air bladder component.

In another aspect, the present disclosure is directed to a method for customizing a cushioning sole system for an article of footwear. The method comprises: receiving information about the geometry of a wearer's foot; forming a lattice, where the lattice has an upper side, and where the upper side is customized according to the information received about the geometry of the wearer's foot. Furthermore, a plurality of air bladder components are incorporated in the lattice.

Other systems, methods, features and advantages of the embodiments will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the embodiments, and be protected by the following claims.

FIGS. 1-4 depict an embodiment of a method of designing a customized sole structure for an article of footwear.FIG. 1 shows the three-dimensional shape of aplantar surface102 of a person'sfoot100 being measured using adata collection apparatus128.

For purposes of reference,foot100, components associated withfoot100, and/or representations of foot100 (such as an article of footwear, an upper, a sole structure, a computer aided design offoot100, and other components/representations) may be divided into different regions. Foot100 may include aforefoot region104, amidfoot region106 and aheel region108.Forefoot region104 may be generally associated with the toes and joints connecting the metatarsals with the phalanges. Midfootregion106 may be generally associated with the metatarsals of a foot.Heel region108 may be generally associated with the heel of a foot, including the calcaneus bone. In addition,foot100 may include alateral side110 and amedial side112. In particular,lateral side110 andmedial side112 may be associated with opposing sides offoot100. Furthermore, bothlateral side110 andmedial side112 may extend throughforefoot region104,midfoot region106, andheel region108. It will be understood thatforefoot region104,midfoot region106, andheel region108 are only intended for purposes of description and are not intended to demarcate precise regions offoot100. Likewise,lateral side110 andmedial side112 are intended to represent generally two sides offoot100, rather than precisely demarcatingfoot100 into two halves.

For consistency and convenience, directional adjectives are also employed throughout this detailed description corresponding to the illustrated embodiments. The term “lateral” or a “lateral direction”116 as used throughout this detailed description and in the claims refers to a direction extending along a width of a component. For example,lateral direction116 offoot100 may extend betweenmedial side112 andlateral side110 offoot100. Additionally, the term “longitudinal” or a “longitudinal direction”114 as used throughout this detailed description and in the claims refers to a direction extending a length of a footwear part orfoot100. In some embodiments,longitudinal direction114 may extend fromforefoot region104 toheel region108 offoot100. As noted earlier, it will be understood that each of these directional adjectives may also be applied to individual components of an article of footwear, such as an upper and/or a sole structure. Avertical direction118 refers to the direction perpendicular to a horizontal surface defined bylongitudinal direction114 andlateral direction116.

Furthermore,foot100 may include a medialarch area120, associated with an upward curve alongmedial side112 ofmidfoot region106, and a lateralarch area122, associated with an upward curve alonglateral side110 ofmidfoot region106. The region corresponding to lateralarch area122 is best seen inFIG. 2, which illustrates a computer screen image of digitized three-dimensional foot data. As described below, the curvature of medialarch area120 and lateralarch area122 may vary from one foot to another. In addition,foot100 includes atransverse arch124 that extends inlateral direction116 nearforefoot region104 alongplantar surface102.Foot100 also includes aheel prominence126, which is the prominence located inheel region108 offoot100. As shown inFIG. 1,foot100 is illustrated as a left foot; however, it should be understood that the following description may equally apply to a mirror image of a foot or, in other words, a right foot.

Although the embodiments throughout this detailed description depict components configured for use in athletic articles of footwear, in other embodiments the components may be configured to be used for various other kinds of footwear including, but not limited to: hiking boots, soccer shoes, football shoes, sneakers, running shoes, cross-training shoes, rugby shoes, basketball shoes, baseball shoes as well as other kinds of shoes. Moreover, in some embodiments, components may be configured for various kinds of non-sports related footwear, including, but not limited to: slippers, sandals, high heeled footwear, loafers as well as any other kinds of footwear.

Components associated with an article of footwear are generally made to fit various sizes of feet. In the embodiments shown, the various articles are configured with approximately the same footwear size. In different embodiments, the components could be configured with any footwear sizes, including any conventional sizes for footwear known in the art. In some embodiments, an article of footwear may be designed to fit the feet of a child. In other embodiments, an article of footwear may be designed to fit the feet of an adult. Still, in other embodiments, an article of footwear may be designed to fit the feet of a man or a woman.

Referring toFIGS. 1 and 2, a first step of the present method is to collect data related tofoot100, such as using a barefoot pressure measurement or other data, from the person being measured ondata collection apparatus128.Data collection apparatus128 may include provisions for capturing information about an individual's feet. Specifically, in some embodiments,data collection apparatus128 may include provisions to capture geometric information about one or more feet. This geometric information can include size (e.g., length, width and/or height) as well as three-dimensional information corresponding to the customer's feet (e.g., forefoot geometry, midfoot geometry, heel geometry and ankle geometry). In at least one embodiment, the captured geometric information for a customer's foot can be used to generate a three-dimensional model of the foot for use in later stages of manufacturing. In particular, the customized foot information can include at least the width and length of the foot. In some cases, the customized foot information may include information about the three-dimensional foot geometry. Customized foot information can be used to create a three-dimensional model of the foot. Embodiments may include any other provisions for capturing customized foot information. The present embodiments could make use of any of the methods and systems for forming an upper disclosed in Bruce, U.S. patent application Ser. No. 14/565,582, filed Dec. 10, 2014, and titled “Portable Manufacturing System for Articles of Footwear” the entirety of which is herein incorporated by reference. Some embodiments could use any of the systems, devices and methods for imaging a foot as disclosed in Gregory et al., U.S. Patent Publication Number 2013/0258085, published Oct. 3, 2013 and titled “Foot Imaging and Measurement Apparatus,” the entirety of which is herein incorporated by reference.

InFIG. 2, ascreen202 displays ascan200 of plantar pressure distributions forfoot100. Scan200 may provide a measured foot image with various distinct regions to indicate the pressure applied byfoot100 alongplantar surface102, including a firstplantar pressure area204, a secondplantar pressure area206, a thirdplantar pressure area208, a fourthplantar pressure area210, and a fifthplantar pressure area212. An additionalplantar pressure area214 is indicated whereplantar surface102 did not make an impressionable contact withsurface130 ofdata collection apparatus128. In some embodiments, colors (not shown inFIG. 2) can be included inscan200 to more readily distinguish variations within the measured pressure data. It should be noted that in other embodiments, different, fewer, or more plantar pressure areas may be measured or indicated.

As seen inFIG. 2, in some embodiments, the data collected may include scan200 offoot100. In some embodiments, scan200 may be used to assess the three-dimensional shape and obtain digital data in a two-dimensional or a three-dimensional reference frame. In other embodiments, scan200 can provide a baseline shape for a footwear component. In one embodiment, three-dimensional scanned images may be used to measure the overall shape of a person's feet, and obtain two-dimensional measurements such as an outline, length, and width offoot100. Obtaining foot geometry can establish a baseline record for the person in one embodiment. In some embodiments, other input may also be provided to supplement information regarding the person being measured. In different embodiments, additional data such as toe height information may also be obtained. In other embodiments, plaster casts of a person's foot may be taken and digitized. Additionally, other digital or imaging techniques which may be employed to capture two and three-dimensional foot shape and profile can be used to construct and/orsupplement scan200. In other embodiments, the person seeking a measurement offoot100 may provide answers to questions describing the person's physical characteristics, limitations and personal lifestyle, which may impact design of the various parts described herein.

A sole structure may provide one or more functions for an article of footwear. InFIG. 3, an image of a template of asole structure300 is displayed on ascreen302. In some embodiments,sole structure300 may attenuate ground reaction forces when compressed between the foot and the ground during walking, running or other ambulatory activities. The configuration ofsole structure300 may vary significantly in different embodiments to include a variety of conventional or non-conventional structures. In some cases, the configuration ofsole structure300 can be selected or customized according to one or more types of ground surfaces on whichsole structure300 may be used. Examples of ground surfaces include, but are not limited to: natural turf, synthetic turf, dirt, as well as other surfaces.

Upon obtaining measurements offoot100,sole structure300 may be adjusted or altered in different embodiments. As seen inFIG. 4, using the data collected from the steps above, a customsole structure400 may be further designed. In some embodiments, the design may utilize an application of an integrated computer aided design such as a computer automated manufacturing (CAD-CAM) process.Sole structure300, or any other template previously selected, may be provided as an input to the computer design program. In one embodiment, the three dimensional foot shape data fromscan200 is also provided to the program.

In different embodiments, scan200 may provide information regarding foot shape and pressure to allow appropriate fit within the article of footwear. The information may be used to form customsole structure400. In some embodiments, data fromscan200 may be superimposed onto a template ofsole structure300. For example, there may be a process of aligning the data representing the plantar pressures offoot100 withsole structure300 and generating a partial or complete design of a customsole structure400. In one embodiment,pressure contour lines406 may be formed during design of customsole structure400. The pressure distribution may be adjusted to a ‘best-fit’ position based upon user input in some embodiments. In one embodiment, after the plantar pressure distribution comprisingpressure contour lines406 is aligned with the template ofsole structure300, the aligned data may be applied to production of customsole structure400.

In different embodiments,sole structure400 may include various modifications. Modifications may includecontours forming elevations408,depressions410, openings, and/or combinations of bothelevations408 anddepressions410. Customized modifications may provide individual users with a wider range of comfort and fit. For example, different users may have differences in the height of the arch offoot100. As described above,foot100 may include multiple arches. Generally, the arch is a raised curve on the bottom surface offoot100. When the tendons offoot100 pull a normal amount,foot100 generally forms a moderate or normal arch. However, when tendons do not pull together properly, there may be little or no arch. This is called “flat foot” or fallen arch. Over-pronation of a foot may be common for those with flat feet. The framework of a foot can collapse, causing the foot to flatten and adding stress to other parts of the foot. Individuals with flat feet may need orthotics to control the flattening of the foot. Moreover, the opposite may also occur, though high foot arches are less common than flat feet. Without adequate support, highly arched feet tend to be painful because more stress is placed on the section of the foot between the ankle and toes. This condition can make it difficult to fit into shoes. Individuals who have high arches usually need foot support. It should be noted that such variations in arch height are one of many possible examples of customized foot geometry that may be incorporated into a design.

Once a design has been generated, as with customsole structure400, the sole structure may be manufactured. InFIG. 5, a customsole structure500 is being made from a print substance dispersed by a three-dimensional printer502. Generally, customsole structure500 may comprise any type of sole layer. In particular, customsole structure500 may have any design, shape, size and/or color. For example, in embodiments where an article of footwear is a basketball shoe, customsole structure500 could include contours shaped to provide greater support toheel prominence126, as shown inFIG. 1. In embodiments where the article of footwear is a running shoe, customsole structure500 could be configured with contours supportingforefoot region104. In some embodiments, customsole structure500 could further include provisions for fastening to an upper or another sole layer, and may include still other provisions found in footwear sole structures. Also, some embodiments of customsole structure500 may include other materials disposed within customsole structure500, such as air bladders, leather, synthetic materials (such as plastic or synthetic leather), mesh, foam, or a combination thereon.

The material selected for customsole structure500 may possess sufficient durability to withstand the repetitive compressive and bending forces that are generated during running or other athletic activities. In some embodiments, the material(s) may include polymers such as urethane or nylon; resins; metals such as aluminum, titanium, stainless steel, or lightweight alloys; or composite materials that combine carbon or glass fibers with a polymer material, ABS plastics, PLA, glass filled polyamides, stereolithography materials (epoxy resins), silver, titanium, steel, wax, photopolymers and polycarbonate. The custom sole structure may also be formed from a single material or a combination of different materials. For example, one side of customsole structure500 may be formed from a polymer whereas the opposing side may be formed from a foam. In addition, specific regions may be formed from different materials depending upon the anticipated forces experienced by each region.

In some embodiments, customsole structure500 as shown inFIG. 5 may be made from three-dimensional printer502. The phrase “three-dimensional printer” as used throughout this detailed description and in the claims refers to a printing apparatus capable of printing or disposing a print substance that forms a three-dimensional object. Printable material could be associated with any color such as red, blue, green, yellow, white, black, or a combination thereof. Printable material could also be made of toner material made from acrylic, plastic, ink, or any other polymeric material known in the art for printing a three-dimensional object from three-dimensional printer502.

FIG. 5 illustrates three-dimensional printer502. Three-dimensional printer502 could be, for example, a MakerBot® Repliactor™ 2. Three-dimensional printer502 is connected to a power source (not shown) in order to supply a current to three-dimensional printer502. Three-dimensional printer502 further includes aprint head508 capable of moving in three dimensions and disposing a print substance forming a three-dimensional object, including a sole structure or other portions of an article of footwear. In the embodiment shown inFIG. 5,print head508 is capable of delivering aprintable material504 onto asurface510 of three-dimensional printer502 in order to form portions of an article. In different embodiments, three-dimensional printer502 is capable of printing multiple printable materials of varying densities and bond strengths. For example, firstprintable material504 could have a first density and first bond strength, and a second printable material (not shown) could have a second density and second bond strength that differs from firstprintable material504. It should be understood a more dense printable material or a printable material having a higher bond strength may create a more rigid structure made to withstand additional tearing, breaking, bending, and/or deforming.

FIG. 5 shows a portion of customsole structure500 being printed in three-dimensional printer502. Three-dimensional printer502 usesprintable material504 to print customsole structure500. Still, in other embodiments, customsole structure500 could be made from a combination of firstprintable material504 and other printable materials.

The embodiments described above generally incorporate a three-dimensional printer in order to print custom sole structures. However, in other embodiments, these structures could be manufactured by means other than a three-dimensional printer. For example, other embodiments could use injection molding. Further, attachment of various portions of custom sole structure could include ultrasonic welding or radio frequency welding in order to create an upper having attached portions and fastener receiving portions.

In different embodiments, customsole structure500 may be configured with one or more structures or designs in order to achieve, for example, a certain look or function. In the embodiment shown inFIG. 6, a first custom sole structure600 includes afirst lattice structure602. It should be noted that while these variations, features, and structures are described initially in relation to first custom sole structure600, they may be applicable to any other custom sole structures described in this detailed description.

InFIG. 6, afirst surface624 is provided on anupper side618 offirst lattice structure602, and asecond surface626 is provided on abottom side620first lattice structure602. Together,first surface624 andsecond surface626 comprise anexterior surface614 offirst lattice structure602. Disposed alongfirst surface624 is a plurality oflattice apertures610. In some embodiments,lattice apertures610 may be disposed on both sides offirst lattice structure602, so that a plurality oflattice apertures610 is also disposed alongsecond surface626. In other embodiments,lattice apertures610 may be disposed on only one side offirst lattice structure602.

As illustrated in the figures,lattice apertures610 are disposed over substantially the entire length and width offirst lattice structure602. In some embodiments, multiple rows oflattice apertures610 may be disposed alongfirst lattice structure602. In the embodiment ofFIG. 6, approximately forty-one rows oflattice apertures610 are depicted. However, in other embodiments, there may be a fewer or greater number of rows oflattice apertures610. The number of rows may be greater for sole structures designed for larger footwear sizes, and less for sole structures designed for smaller footwear sizes. In other embodiments,lattice apertures610 may be disposed on only some portions offirst lattice structure602.Lattice apertures610 may be arranged to correspond to and/or support the contours ofplantar surface102 offoot100 as described above with reference toFIGS. 1-4.

In some embodiments,lattice apertures610 may be in a staggered arrangement, as seen inFIG. 6. Thus, along a generally horizontal plane,exterior surface614 may include repeated openings associated withlattice apertures610. In some embodiments,lattice apertures610 may be arranged in rows and columns alongexterior surface614 ofupper side618 and/orbottom side620, where rows extend laterally across first custom sole structure600, and columns extend longitudinally across first custom sole structure600. A plurality oflattice apertures610 may have a configuration of an array, having a number of rows N and a number of columns M, implying positions for a number of lattice apertures N×M. In some embodiments, there may be between four and thirteen columns, and between thirty and fifty rows. In one embodiment, there may be between 120 and 650lattice apertures610 disposed along one side ofexterior surface614. Other configurations of arrays oflattice apertures610 may imply positions formore lattice apertures610 or forfewer lattice apertures610 than in the initial configuration.

A magnifiedarea604 of first custom sole structure600 showsfirst lattice structure602 withlattice apertures610. In first custom sole structure600,lattice apertures610 have a rounded shape. In other embodiments, as discussed further below,lattice apertures610 may include a wide variety of other geometries.Lattice apertures610 may also have a cross-sectional shape that is round, square, or triangular, for example. In some embodiments,lattice apertures610 may have a variety of geometric shapes that may be chosen to impart specific aesthetic or functional properties to first custom sole structure600.

First custom sole structure600 also includes aninterior area612 that lies betweenbottom side620 andupper side618 and is bounded by aperipheral side632. In some embodiments,lattice apertures610 extend frominterior area612 of first custom sole structure600 to anexterior surface614. In other configurations, two or more oflattice apertures610 may be interconnected with each other.

In some embodiments,interior area612 may be substantially hollow. In other embodiments, as inFIG. 6, there may be a plurality ofvertical portions608 disposed withininterior area612, forming hollow areas or interstices622 withininterior area612. Interstices622 may be chambers or compartments that are formed within first custom sole structure600. In some embodiments,vertical portions608 may extend downward in a generallyvertical direction118 fromupper side618 of first custom sole structure600 towardbottom side620. In one embodiment,vertical portions608 may be curved as they extend downward. In another embodiment, one or morevertical portions608 may be curved to form a generally semi-circular piece or half-circular piece. In some embodiments, two or morevertical portions608 adjacent to one another may be disposed so that they help form interstices622. In other embodiments, two or more adjacentvertical portions608 may be disposed so that they curve away from one another. In some embodiments, when multiplevertical portions608 are connected to and/or joined toexterior surface614, as depicted inFIG. 6, three-dimensional, interconnectedfirst lattice structure602 is formed.

Along the edges of first custom sole structure600,peripheral side632 is shown.Peripheral side632 may be smooth, rough, jagged, or may be otherwise irregular in different embodiments.Peripheral side632 may correspond to the surface surrounding the outer boundary or perimeter of first custom sole structure600, and be similar to a vertical wall or frame that is disposed betweenupper side618 andbottom side620 along its perimeter. InFIG. 6,peripheral side632 is defined in part by repeatingvertical portions608. In different embodiments,peripheral side632 may include a variety of shapes and structural features. InFIG. 6,peripheral side632 includes a series of partially bounded areas, including a first boundedarea628 and an adjacent second boundedarea630. First boundedarea628 is bounded on three sides to form a curved shape, and has a concave opening alongbottom side620. Second boundedarea630 is also bounded on three sides to form a relatively more defined U-shape that has a convex opening alongbottom side620. In other embodiments, first boundedarea628 and second boundedarea630 may differ from one another or may be substantially similar, and may have different geometries.

In different embodiments,first lattice structure602 may be straight or curved along its length. Portions offirst lattice structure602 may also be altered geometrically to have a round, oval, cubic, or pyramidal contour, for example. In some embodiments,first lattice structure602 of first custom sole structure600 is integrally constructed as a single piece during the manufacture process. In other embodiments, first custom sole structure600 may be manufactured in various pieces and assembled and/or joined together.

It should be noted that in different embodiments, the design of the lattice structure may provide various structural features to the custom sole structure. In some embodiments, a few of which are described below, the lattice structure may include a wide variety of geometries, including a repeated arrangement of hollow cubes, spheres, and other regular or irregular shapes within the lattice structure. In some embodiments, the shapes may be open along their sides, and exposed along the exterior surface throughlattice apertures610. The geometry may be consistent across the custom sole structure, or it may include multiple geometries disposed in various portions of the custom sole structure. The included shapes may also be similar in size within the custom sole structure, or they may vary in size, so that one portion of the custom sole structure includes larger apertures and other portions include relatively smaller apertures.

In different embodiments,first lattice structure602 and other lattice structures described herein may include structural features that allowfirst lattice structure602 to support the weight of the wearer, as well as provide space for insertion or inclusion of further sole components, such as microbladders, cushioning elements, and other materials.

Various lattice structures as described here can provide a custom sole structure with specialized responses to ground reaction forces. In one embodiment, the lattice structure may attenuate and distributes ground reaction forces. For example, when a portion of the custom sole structure contacts the ground, the lattice structure can attenuate the ground reaction forces. The lattice structure may have the capacity to distribute the ground reaction forces throughout a substantial portion of the custom sole structure. The attenuating property of this type of structure can reduce the degree of the effect that ground reaction forces have on the foot, and the distributive property distributes the ground reaction forces to various portions offoot100. In some embodiments, such features may reduce the peak ground reaction force experienced byfoot100.

In other embodiments, the lattice structure designs disclosed in this description may also include provisions to achieve a non-uniform ground reaction force distribution. For example, the ground reaction force distribution of a custom sole structure could provide a wearer with a response similar to that of barefoot running, but with attenuated ground reaction forces. That is, the custom sole structure could be designed to impart the feeling of barefoot running, but with a reduced level of ground reaction forces. Additionally, the ground reaction forces could be more concentrated inmedial side112 offoot100 than alonglateral side110 offoot100, thereby reducing the probability that the foot will over-pronate or imparting greater resistance to eversion and inversion of the foot.

Furthermore, there may be vibrational properties of the custom sole structure that enhance the user experience. Whenarticle100 impacts the ground, the lattice structure can compress and vibrate. The vibrational frequency of the lattice structure may be dependent upon the configuration of the lattice structure (e.g., the manner in which the vertical portions and the horizontal portions are arranged to form geometrical patterns or hollow areas). Thus, the lattice structure may also be customized to have vibrational properties that are specific to the needs of the individual wearer or the activity for which the footwear is intended to be used.

There are many possible variations in design that may be included in the custom sole structure. An alternative embodiment of the custom sole structure is illustrated inFIGS. 7-13, and will be discussed in further detail below.FIGS. 7-9 provide three depictions of a custom sole structure as they may be designed to support three different foot types. InFIG. 7, afirst foot702 with a relatively “normal arch” is shown. The arch area described here is typically associated with the area corresponding with sixth plantar pressure area214 (seeFIG. 2). A normal arch generally has anoticeable curve704 inward, but not by more than ¾ of an inch. A normal arch is the most common type of foot arch, and is also the least susceptible to injury if provided with proper footwear. A second customsole structure700 that has been custom manufactured forfirst foot702 is shown beneathfirst foot702. In particular,upper side618 of second customsole structure700 is contoured to matchinward curve704. A customized sixthplantar pressure area714 has an area ofmaximum elevation718 associated with afirst height706.

FIGS. 8 and 9 illustrate two other foot types. InFIG. 8, a “high arch” is illustrated in asecond foot802. A high arch can be associated with a higherinward curve804 than that of a normalarch curve704 as shown inFIG. 7.Plantar surface102 ofsecond foot802 curves upward to a greater degree thanplantar surface102 offirst foot702. Individuals with high arches tend to supinate or underpronate, so thatsecond foot802 typically rolls outwards during running. High arched feet generally require running shoes with a higher support and a softer and/or flexible sole that absorbs shock. A corresponding third customsole structure800 is shown belowsecond foot802 that includes anupper side618 shaped to support the high arch ofsecond foot802. A customized sixthplantar pressure area814 has an area with amaximum elevation818 associated with asecond height806 that is greater thanfirst height706.

InFIG. 9, a low or “flat arch” is depicted inthird foot902. Generally, flat feet have anarch curve904 that is substantially flatter relative to a high arch or a normal arch. Thus, much of the bottom ofthird foot902 can be flat. Beneaththird foot902 is a fourth customsole structure900. Individuals who are flat-footed generally overpronate, so that the feet typically roll inward during running. Individuals with flat feet often need shoes that assists in maintaining stability and motion control and provides additional support to midfootregion106. A corresponding fourth customsole structure900 is shown belowthird foot902 that includes anupper side618 shaped to provide adequate support for the flattened arch ofthird foot902. A customized sixthplantar pressure area914 has an area with amaximum elevation918 associated with athird height906 that is less thanfirst height706. In different embodiments, each customized sole structure may include further variations not depicted in the figures. Some variations may include differences in shape, size, contour, elevations, depressions, curvatures, and other variations.

InFIG. 10, another embodiment is depicted in a fifthcustom sole structure1000. Fifthcustom sole structure1000 includes asecond lattice structure1002. As seen inFIGS. 10-12, in some embodiments, along a generally horizontal plane,exterior surface614 of fifthcustom sole structure1000 may includelattice apertures610. In fifthcustom sole structure1000,lattice apertures610 have a rounded shape. In other embodiments,lattice apertures610 may include other shapes, as described with reference toFIG. 6.

As discussed with reference toFIG. 6, fifthcustom sole structure1000 inFIG. 10 includesinterior area612 that extends betweenbottom side620 andupper side618 and is bounded by aperipheral side1030. A magnifiedarea1018 of fifthcustom sole structure1000 showssecond lattice structure1002 withlattice apertures610.Second lattice structure1002 is comprised of a series of repeating curved portions1004 (similar tovertical portions608 described above) disposed betweenupper side618 andbottom side620 andperipheral side1030.

In one embodiment,peripheral side1030 of fifthcustom sole structure1000 can include a plurality ofperforations1028.Perforations1028 are openings that extend fromexterior surface614 ofperipheral side1030 to the interior surface of peripheral side1030 (i.e., forming a kind of tessellated framework along the interior portion of peripheral side1030). The plurality ofperforations1028 may be of different shapes or different sizes, or substantially uniform or any combination thereof. In one embodiment,perforations1028 may include sharper edges relative to the openings associated withlattice apertures610, including square and triangular shapes. In some areas ofperipheral side1030 there may bemore perforations1028 relative to other areas ofperipheral side1030.

In some embodiments,interior area612 may be substantially hollow. In other embodiments, there may be a plurality ofcurved portions1004 disposed withininterior area612, adjacent to interstices1014.Interstices1014 may be similar to chambers or compartments within fifthcustom sole structure1000. In some embodiments,curved portions1004 may extend downward in a generallyvertical direction118 fromupper side618 of fifthcustom sole structure1000 towardbottom side620. In one embodiment,curved portions1004 may include edges or change orientation as they extend downward. In another embodiment, one or morecurved portions1004 may form a generally semi-circular piece or half-circular piece. In some embodiments, two or morecurved portions1004 adjacent to one another may be disposed so that they help forminterstices1014 withininterior area612 by curving toward one another. In other embodiments, two or more adjacentcurved portions1004 may be disposed so that they curve away from one another.

In the embodiment ofFIG. 10,exterior surface614 is comprised of afirst surface1006 onupper side618, asecond surface1008 onbottom side620, and athird surface1010 along the outer perimeter of fifthcustom sole structure1000, associated withperipheral side1030.Second surface1008 may be more visible inFIG. 13. Disposed alongfirst surface1006 are one ormore lattice apertures610. In some embodiments,lattice apertures610 may be disposed on both sides ofsecond lattice structure1002, so thatlattice apertures610 are also disposed alongsecond surface1008. In other embodiments,lattice apertures610 may be disposed on only one side ofsecond lattice structure1002. In one embodiment,lattice apertures610 may be disposed only alongfirst surface1006 orsecond surface1008. In another embodiment,lattice apertures610 may also be disposed alongthird surface1010.

In different embodiments,lattice apertures610 may be disposed in various arrangements alongexterior surface614, as discussed previously with reference toFIG. 6. For example, in one embodiment,lattice apertures610 may be disposed in a relatively random configuration. In other embodiments,lattice apertures610 apertures may be linearly arranged in rows and columns alongexterior surface614. In some embodiments,lattice apertures610 may be in a staggered arrangement, as seen inFIG. 10.

In some embodiments wherelattice apertures610 are disposed along multiple surfaces,lattice apertures610 may have varying sizes with respect to one another, or they may have the same size. For example,lattice apertures610 disposed onfirst surface1006 may be larger thanlattice apertures610 disposed onsecond surface1008. Furthermore,lattice apertures610 may vary with respect to one another in shape along each surface, or the shapes may each be the same. For example, inFIG. 10,first surface1006 andsecond surface1008 includelattice apertures610 that are generally rounded or circular. In other embodiments,lattice apertures610 may differ from one another in both size and shape along the same surface.

In some embodiments,second lattice structure1002 may also be altered or designed to have a round, oval, cubic, or pyramidal contours, for example, or include other regular or irregular geometry.

As described earlier, in some embodiments, fifthcustom sole structure1000 may include one ormore interstices1014 withinsecond lattice structure1002.Interstices1014 may remain substantially hollow or, during or after manufacture,interstices1014 may be partially or substantially filled with one or more materials, substances, and/or support components. In some embodiments,support components1016 may comprise an air bladder. In other embodiments,support components1016 may comprise an air cushioning element. It should be noted thatsupport components1016 may also be referred to as air bladder components for purposes of this description. In different embodiments, the material that can fill or be included withininterstices1014 can vary widely. In one embodiment, the material may include one ormore support components1016. In the embodiment ofFIGS. 10 and 11,support components1016 include afirst support component1012 and asecond support component1020.

In different embodiments,support components1016 may be incorporated into a lattice structure in various ways. In some embodiments,support components1016 may be inserted or compressed throughlattice apertures610 after a lattice structure has been formed. In some embodiments, there may be temporary deformation ofsupport components1016 before or during insertion intointerstices1014. In other embodiments,support components1016 can be included in the lattice structure during manufacture or printing of lattice structure. For example,support components1016 may be disposed in partially formed interstices1014 ofsecond lattice structure1002 as it is manufactured, and once interstices1014 have been filled, the manufacture ofsecond lattice structure1002 may be completed. In another embodiment, one side or portion ofthird surface1010 may be left open for insertion ofsupport components1016. In other embodiments, an opening may be provided alongfirst surface1006 orsecond surface1008 for insertion ofsupport components1016. Upon formation of substantially the entiresecond lattice structure1002,support components1016 may be inserted or placed withininterior area612 ofsecond lattice structure1002 through the provided opening. In some embodiments, the opening may be at least partially filled, sealed, or otherwise closed following the insertion ofsupport components1016. In other embodiments,support components1016 may be maintained in an environment with greater atmospheric pressure than standard, normal or ambient atmospheric pressure. After the manufacture ofsecond lattice structure1002,support components1016 may be inserted intosecond lattice structure1002. Once inserted,support components1016 may be exposed to standard atmospheric pressure, which will allowsupport components1016 to expand to the appropriate size withinsecond lattice structure1002. Similarly, in another embodiment,support components1016 may be stored at low temperatures relative to normal or room temperature, and upon insertion intosecond lattice structure1002, the increase in temperature will permitsupport components1016 to expand to a size that allowssupport components1016 to fit snugly and securely withininterstices1014.

Support components1016 may vary in structural design. In different embodiments, the shape and sizes ofsupport components1016 may differ, as will also be discussed further below with reference toFIGS. 14 and 15. InFIGS. 10 and 11,first support component1012 andsecond support component1020 include a generally spherical shape. In other embodiments,support components1016 may include a prism, cube, pyramidal, cylindrical, cone or other shape. When incorporated into fifthcustom sole structure1000 as shown inFIG. 11,support components1016 may have a shape and size that fits relatively securely and firmly withininterstices1014.

As shown inFIGS. 10-12,lattice apertures610 alongupper side618 and/orbottom side620 may include openings, recesses, or cavities for substantially conforming to regions associated with the top and/or bottom ofsupport components1016. In some embodiments,lattice apertures610 are in fluid communication withinterstices1014. In one embodiment,first support component1012 is disposed in afirst aperture1022 associated with an interstice, andsecond support component1020 is disposed in asecond aperture1024 associated with an interstice. In other words,first aperture1022 is in fluid communication with a corresponding interstice, andsecond aperture1024 is also in fluid communication with an interstice. This can be seen in greater detail in a magnifiedarea1100 inFIG. 11. Athird support component1102 is disposed in an interstice of fifthcustom sole structure1000, the top surface ofthird support component1102 is visible through athird aperture1106. Afourth support component1104 is similarly disposed in fifthcustom sole structure1000 where the top surface offourth support component1104 is visible through afourth aperture1108. Thus, in some embodiments, after a support component has been inserted or disposed within fifthcustom sole structure1000 where some portion of the support component may be seen protruding out of a corresponding aperture. In the case offirst support component1012, a relatively small portion offirst support component1012 is visible and exposed alongexterior surface614. The amount by which a portion ofsupport components1016 project up fromlattice apertures610 alongupper side618 may vary. The protruding portion ofsupport components1016 may project to varying heights aboveupper side618, as long as the height does not interfere with the placement and/or relative comfort of the foot in the corresponding article of footwear. In other embodiments,support components1016 may be completely enclosed withininterior area612 so that there is no region protruding aboveupper side618.

In different embodiments,support components1016 may be arranged withininterstices1014 so that a majority ofinterstices1014 disposed withininterior area612 are provided withsupport components1016. For instance,support components1016 may provide approximately 60% or more of the volume ofinterior area612. In another example,support components1016 may provide approximately 70% or more of the volume ofinterior area612. In one embodiment,support components1016 may comprise over 80% of the volume ofinterior area612. In another embodiment,support components1016 may comprise at least 90% of the volume ofinterior area612.

Upon inclusion ofsupport components1016 in fifthcustom sole structure1000, there may be a plurality ofsupport components1016 disposed withininterstices1014. In some embodiments, fifthcustom sole structure1000 may include between 100 and 250support components1016. In another embodiment, fifthcustom sole structure1000 may include between 150 and 200support components1016. In one embodiment, there may be at least one support component for each fully formedinterstice1014. For purposes of this disclosure, a fully formed interstice refers to aninterstice1014 that is not adjacent toperipheral side1030, and is completely enclosed.Interstices1014 disposed nearperipheral side1030 may be abbreviated or otherwise include an irregular or partially formed geometry and/or be associated withlattice apertures610 that are partially formed. It should also be noted that in some embodiments, there may be moremultiple support components1016 disposed within the space (hollow area1014) defined by asingle lattice aperture610.

In different embodiments,support components1016 may include a fluid. In one embodiment, one ormore support components1016 may be sealed to contain a pressurized fluid. In some embodiments, the fluid may be air or a type of gas. For example,first support component1012 andsecond support component1020 can each enclose a fluid that can be at atmospheric pressure or that can be pressurized between zero and three-hundred-fifty kilopascals (i.e., approximately fifty-one pounds per square inch) or more, with a pressure of zero representing the ambient air pressure at sea level. In addition to air and nitrogen, the fluid contained byfirst support component1012 andsecond support component1020 can include octafluorapropane or be any of the gasses disclosed in U.S. Pat. No. 4,340,626 to Rudy, such as hexafluoroethane and sulfur hexafluoride, for example.

In some embodiments, one ormore support components1016 may include chambers or sealed spaces that enclose pressurized fluid, thereby providing cushioning and support to the foot. In some embodiments, the pressures of fluid withinsupport components1016 may be advantageously selected and varied to provide a desired amount of cushioning and support for different portions of a foot. For example, the pressurized fluid withinsupport components1016 inheel region108 may be selected to be at a higher pressure than the pressurized fluid included withinsupport components1016 inforefoot region104, in order to provide greater cushioning and support to a heel portion of a foot. In another configuration, the pressure of the pressurized fluid may vary from support component to support component. For example, the range of pressure in the plurality ofsupport components1016 disposed within fifthcustom sole structure1000 may gradually decrease fromheel region108 to forefootregion104.

A wide range of polymer materials may be utilized for thesupport components1016 discussed herein, including various polymers that can resiliently retain a fluid, such as air or another gas. In selecting materials forsupport components1016, engineering properties of the material (e.g., tensile strength, stretch properties, fatigue characteristics, dynamic modulus, and loss tangent) as well as the ability of the material to prevent the diffusion of the fluid contained may be considered. In some embodiments, thermoplastic urethane, polyurethane, polyester, polyester polyurethane, and polyether polyurethane may be used to formsupport components1016.Support components1016 may also be formed from a material that includes alternating layers of thermoplastic polyurethane and ethylene-vinyl alcohol copolymer, as disclosed in U.S. Pat. Nos. 5,713,141 and 5,952,065 to Mitchell, et al. A variation upon this material may also be utilized, wherein layers include ethylene-vinyl alcohol copolymer, thermoplastic polyurethane, and a regrind material of the ethylene-vinyl alcohol copolymer and thermoplastic polyurethane. Another suitable material forsupport components1016 is a flexible microlayer membrane that includes alternating layers of a gas barrier material and an elastomeric material, as disclosed in U.S. Pat. Nos. 6,082,025 and 6,127,026 to Bonk, et al. Additional suitable materials are disclosed in U.S. Pat. Nos. 4,183,156 and 4,219,945 to Rudy. Further suitable materials include thermoplastic films containing a crystalline material.

Support components1016 can be included ininterior area612 of fifthcustom sole structure1000 so that they are disposed fromforefoot region104 toheel region108 and also fromlateral side110 tomedial side112, thereby corresponding with a general outline offoot100. Whenfoot100 is located within an article of footwear that includes fifthcustom sole structure1000,support components1016 can extend under a majority offoot100 or substantially all offoot100.Support components1016 may be arranged in a manner that helps attenuate ground reaction forces that are generated when fifthcustom sole structure1000 is compressed betweenfoot100 and the ground during various ambulatory activities, such as running and walking.

Such a configuration of custom sole structures can provide resilient support that provides many advantages. For example, the inclusion ofsupport components1016 within fifthcustom sole structure1000 wheresupport components1016 include an air bladder or are fluid-filled may provide benefits associated with a lighter article of footwear. In some embodiments, the use ofsupport components1016 in orthotics for an article of footwear can help support weakened areas offoot100 and assist the user in each step. While a relatively rigid material, as included in fifthcustom sole structure1000, can provide functional support to the foot, softer or more flexible materials can absorb the loads put on the foot and provide protection. Such softer materials, such assupport components1016, can absorb the loads placed onfoot100, increase stabilization, and take pressure off uncomfortable or sore spots of the feet. In one embodiment, an orthotic can include a relatively soft interior material reinforced with a more rigid support such as that comprisingsecond lattice structure1002. This type of orthotic may offer both functional support and protection.

FIG. 12 provides a cut-away view of fifthcustom sole structure1000 along the axis labeled “12” inFIG. 11. In different embodiments,interstices1014 bounded by the openings provided bylattice apertures610 may have a cross-sectional shape that is partially round, cylindrical, square, or triangular, or another irregular shape, for example. In some embodiments,interstices1014 may include a variety of geometrical shapes that may be chosen to impart specific aesthetic or functional properties to fifthcustom sole structure1000. As can be seen in a magnifiedarea1200,second lattice structure1002 includescurved portions1212 anddiagonal portions1210 that together form an internal structure that can contain, receive, or otherwise holdsupport components1016.

Furthermore, as noted above,support components1016 may have a uniform size or may vary in size. In one embodiment,support components1016 may be generally spherical and similar in size. InFIG. 12, afifth support component1202 and a neighboringsixth support component1204 are shown in cross-section in magnifiedarea1200.Fifth support component1202 andsixth support component1204 are each portions of a sphere. The interior space offifth support component1202 andsixth support component1204 can be hollow or generally empty, or may contain a fluid or another relatively soft material. When filled with fluid such as air,fifth support component1202 may provide athird interstice1206 with the support of an air bladder, andsixth support component1204 may provide afourth interstice1208 with the support of an air bladder. The air bladders can help absorb loads or other forces applied to fifthcustom sole structure1000.

In other embodiments,support components1016 inmidfoot region106 and inheel region108 may have a larger cross-sectional shape or a larger diameter thansupport components1016 inforefoot region104. In another example,support components1016 inheel region108 may have a larger cross-sectional shape or diameter thansupport components1016 inmidfoot region106 andsupport components1016 inforefoot region104, andsupport components1016 inforefoot region104 may have a larger cross-sectional shape or diameter thansupport components1016 inmidfoot region106. In another example,support components1016 inmidfoot region106 may have a larger cross-sectional shape or diameter thansupport components1016 inheel region108 andsupport components1016 inforefoot region104.

FIG. 13 is an isometric view ofbottom side620 ofsecond lattice structure1002. Afirst surface1006 is provided onexterior surface614 ofupper side618, and asecond surface1008 is provided onexterior surface614 ofbottom side620. Disposed alongsecond surface1008 are one ormore lattice apertures610. As described with reference toFIG. 10, in some embodiments,lattice apertures610 may be disposed on both sides ofsecond lattice structure1002, so thatlattice apertures610 are also disposed alongfirst surface1006 andsecond surface1008. In some embodiments, the structure associated withbottom side620 may be similar to the structure associated withupper side618, as described above. In other embodiments,bottom side620 may differ fromupper side618 in geometry, lattice aperture pattern, material, and other features. In the embodiment ofFIG. 13,bottom side620 is flat relative to the contours discussed in relation toupper side618. In other embodiments,bottom side620 may also include various customizable contours or configurations.

In a third example, an embodiment of a sixthcustom sole structure1400 is depicted inFIGS. 14 and 15. Sixthcustom sole structure1400 includes athird lattice structure1402, including afirst surface1408, a second surface1426 (represented bybottom side620 of sole structure1400), athird surface1410, and afourth surface1412.First surface1408 is associated withupper side618 andsecond surface1426 is associated withbottom side620.Third surface1410 andfourth surface1412 are associated with generally opposite sides ofperipheral side1404, wherethird surface1410 faces inward, andfourth surface1412 faces outward. In sixthcustom sole structure1400, a series of repeatedlath portions1406 are joined to formthird lattice structure1402.Lath portions1406 disposed alongperipheral side1404 can be seen to formperforations1422 in a magnifiedarea1424. In some embodiments,perforations1422 can be generally similar in shape and/or size tolattice apertures610 disposed alongfirst surface1408 andsecond surface1426. In other embodiments,perforations1422 may differ in shape and/or size fromlattice apertures610. In the embodiment ofFIG. 14,perforations1422 may be more narrow and diamond-shaped thanlattice apertures610.

Depicted above sixthcustom sole structure1400 are a plurality ofsupport components1414. InFIGS. 14 and 15,support components1414 include afirst support component1416, asecond support component1426, athird support component1418, and afourth support component1420. As mentioned earlier,support components1414 may include a variety of geometries and sizes. In some embodiments,first support component1418,second support component1426,third support component1418, andfourth support component1420 may each be a member of a set of similarly shaped components, or components with substantially similar geometry. For example,first support component1416 includes a generally cylindrical shape,second support component1426 includes a generally cuboid shape,third support component1418 includes a generally rectangular prism shape, andfourth support component1420 includes a generally spherical shape. In other embodiments, the includedsupport components1414 may differ from those depicted.

Variation of the shapes ofsupport components1414 may permit custom sole structures to be designed for different uses and capacities. In some embodiments,heel region108 may include a thicker heel in order to raise the heel of the wearer's foot higher than the toes, as is common is some women's footwear. For example, sixthcustom sole structure1400 may be designed for inclusion in footwear such as a women's sandal. In such cases, the portion ofinterior area612 associated withheel region108 of sixthcustom sole structure1400 may be designed to include greater volume relative to the volume associated withinterior area612 offorefoot region104. Furthermore, inFIG. 14, the distance betweenupper side618 andbottom side620 inheel region108 is associated with afirst height1432, and the distance betweenupper side618 andbottom side620 inforefoot region104 is associated with a second height1434. In some embodiments,first height1432 may differ from second height1434. In the embodiment ofFIGS. 14 and 15,first height1432 is greater than second height1434. In other embodiments,first height1432 may be substantially similar to or less than second height1434.

In one embodiment, variations in the heights or volume in different regions of sixthcustom sole structure1400 may provideinterstices1014 that are suited to the variations in the shapes and sizes ofsupport components1414. For example, the cylindrical shape offirst support component1416 may be better suited tointerstices1014 defined byfirst height1432, while the generally spherical shape offourth support component1420 may be suited tointerstices1014 defined by second height1434.

As shown inFIG. 15,support components1414 may be incorporated into sixthcustom sole structure1400.Support components1414 may have shapes and sizes that permits them to fit relatively snugly withininterstices1014 ofinterior area612. In some embodiments,lattice apertures610 alongupper side618 and/orbottom side620 may include recesses or cavities for substantially conforming to top and/or bottom of the various size and/or shapes ofsupport components1414. In one embodiment, shown inFIG. 15,third support component1418 is disposed in an interstice associated with afirst aperture1428, andfourth support component1420 is disposed in an interstice associated with asecond aperture1430.First support component1416 and second support component1426 (not shown inFIG. 15) may also be incorporated into sixthcustom sole structure1400, nearheel region108 and/ormidfoot region106, for example. In some embodiments, afterthird support component1418 has been included within sixthcustom sole structure1400, a region ofthird support component1418 can protrude out offirst aperture1428 so that a relatively small portion ofthird support component1418 is visible and exposed alongexterior surface614. Similarly,other support components1414 may also protrude out of theircorresponding lattice apertures610. The amount by which the top surface ofsupport components1414 project up fromlattice aperture610 alongupper side618 may vary. The top surface ofsupport components1414 may project to varying heights aboveupper side618, as long as the height does not interfere with the placement and/or relative comfort of the foot in the corresponding article of footwear. In other embodiments,support components1414 may be completely enclosed withininterior area612.

Support components1414 may be arranged withininterstices1014 so that a majority ofinterstices1014 disposed withininterior area612 are provided withsupport components1414. For instance,support components1414 may provide approximately 70% or more of the volume ofinterior area612. In another example,support components1414 may provide approximately 80% or more of the volume ofinterior area612.

Upon inclusion ofsupport components1414 in sixthcustom sole structure1400, there may bemultiple support components1414 disposed withininterstices1014. In some embodiments, sixthcustom sole structure1400 may include between 100 and 250support components1414. In another embodiment, sixthcustom sole structure1400 may include between 150 and 200support components1414. In one embodiment, there may be at least onesupport component1414 for each fully formedlattice aperture610. It should be noted that in some embodiments, there may be more than onesupport component1414 disposed within the compartments ofinterstices1014.

InFIG. 16, an article offootwear1600 that includes a seventh customsole structure1608 is depicted with a cut-away view. Seventhcustom sole structure1608 incorporatessupport components1610. Article offootwear1600 may include other elements, such as an upper1602, and additional materials or layers, such as anoutsole1604 and/or aninsole1606. Additional layers may provide a seventh customsole structure1608 with further cushioning and/or support.

Other embodiments or variations of custom sole structures may include other lattice structure designs or various combinations of the above-disclosed designs. It should be noted that the present description is not limited to lattice structures having the geometry offirst lattice structure602,second lattice structure1002, andthird lattice structure1402. In other words, the custom sole structures depicted herein are merely intended to provide an example of the many types of lattice structure configurations that fall within the scope of the present discussion.

While various embodiments have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the embodiments. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any embodiment may be used in combination with or substituted for any other feature or element in any other embodiment unless specifically restricted. Therefore, it will be understood that any of the features shown and/or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the embodiments are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims (12)

What is claimed is:

1. A sole structure for an article of footwear, the sole structure comprising:

a forefoot region;

a heel region;

a midfoot region disposed between the forefoot region and the heel region;

a structure extending between the forefoot region and the heel region and defining a first surface, a second surface formed on an opposite side of the structure from the first surface, a medial side, a lateral side, and a plurality of apertures each defined by a wall extending from the first surface to the second surface of the structure, the apertures tapering in width along a first direction from the first surface to the second surface whereby walls defining adjacent ones of the apertures are joined at the first surface and diverge from each other along the first direction, the plurality of apertures including apertures that extend from the medial side to the lateral side along a first longitudinal axis to define a first pattern of apertures that is repeated along a second longitudinal axis, perpendicular to the first longitudinal axis, across an entire length of the structure from the forefoot region to the heel region; and

a plurality of discrete spherical cushioning elements each disposed in respective ones of the plurality of apertures and having an outer perimeter supported by the wall of the respective aperture in which the cushioning element is disposed such that a portion of each of the cushioning elements is spaced apart from the wall and protrudes from the first surface of the structure.

2. The sole structure ofclaim 1, wherein the cushioning elements are fluid-filled chambers.

3. The sole structure ofclaim 1, wherein the cushioning elements are air-filled chambers.

4. An article of footwear incorporating the sole structure ofclaim 1.

5. The sole structure ofclaim 1, wherein the cushioning elements are spherical.

6. The sole structure ofclaim 1, wherein plurality of apertures are circular.

7. The sole structure ofclaim 1, wherein the plurality of apertures include a constant taper from the first surface to the second surface.

8. An article of footwear incorporating the sole structure ofclaim 1.

9. The sole structure ofclaim 1, wherein the first surface of the structure is an upper surface for receiving a plantar surface of a foot.

10. The sole structure ofclaim 1, wherein the structure includes a peripheral side extending between and bounding the first surface and the second surface, the peripheral side including a plurality of perforations formed therethrough.

11. The sole structure ofclaim 10, wherein the perforations are polygonal.

12. The sole structure ofclaim 1, wherein the first pattern is a row of apertures extending from the medial side to the lateral side, the row of apertures repeated along the second longitudinal axis to define a plurality of columns of the apertures extending from the forefoot region to the heel region.

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